Method of encapsulation

ABSTRACT

A method of encapsulation is provided that comprises covering the article to be encapsulated with an epoxy resin containing discontinuous graphite and/or boron nitride fibers, and curing the epoxy resin, thereby obtaining a product having a low coefficient of linear thermal expansion. The method is particularly useful for encapsulating delicate electrical, optical and mechanical elements that are incapable of withstanding thermal stresses.

United States Patent Dauksys Sept. 23, 1975 [54] METHOD OF ENCAPSULATION 3,658,750 4/1972 Tsukui et al. 260/37 EP 3,679,465 7/1972 Flynn 117/126 GE [75] l Dauksys, Benbrook 3,686,139 8/1972 Lubin 260/37 EP Ohm I 3,689,444 9/1972 Wolfe 117/161 Z8 [73] Assignee: The United states of America as 3,806,489 4/1974 Rleux et al 260/37 EP represented by the Secretary of the Force, Washington, DC Primary Exqmmerl-larry J. Gwmnell Attorney, Agent, or FirmJoseph E. Rusz; Cedric H. 22] Filed: Jan. 7, 1974 Kuhn 21 Appl. No.: 431,198

[-5 7] ABSTRACT [52] Cl 427/58, 427/162. A method of encapsulation is provided that comprises 427/386. 428/413 covering the article to be encapsulated with an epoxy 51] Int. c1. c091) 3/58; i-iolB 3/40 resin Cumming dismminwus graphite and/"r [58} Field Search 26O/37 EP; 117/232; 16 23 nitride fibers, and curing the epoxy resin, thereby ob- 9/1967 Manasia et al 117/l28.4 X

taining a product having a low coefficient of linear thermal expansion. The method is particularly useful for encapsulating delicate electrical, optical and mechanical elements that are incapable of withstanding thermal stresses.

6 Claims, 2 Drawing Figures NIETHOD OF ENCAPSULATION FIELD OF THE INVENTION This invention is concerned with amethod for encapsulating elements that may be subjected to thermal stresses. In one aspect it relates to a potting composition having a low coefficient of thermal expansion.

BACKGROUND OF THE INVENTION A variety of resins, e.g., silicones, fluorocarbons,

polyurethanes and epoxies, are employed to encapsuthe various resins, the epoxies are the ones that are most extensively used. However, epoxy resins have not proven to be completely satisfactory when epoxy-potted components, which are structurally delicate, are exposed to thermally induced compressive forces. Because the coefi'icient of linear thermal expansion of conventional epoxy potting compositions is relatively high, delicate components, such as sensors, may be rendered inoperative by expansion of the compositions upon exposure to such conditions.

It is an object of this invention, therefore, to provide an epoxy potting composition which has a low coefficient of thermal expansion.

Another object of the invention is to provide a method of encapsulation that is particularly adapted for encapsulating delicate components.

Other objects and advantages of the invention will become apparent to those skilled in the art upon consideration of the accompanying disclosure and the drawing, in which:

FIG. 1 illustrates graphically. the effect of fillers on coefficient of linear thermal expansion; and

FIG. 2 illustrates graphically the effect of discontinuous graphite and boron nitride fibers on coefficient of linear thermal expansion. 7

SUMMARY OF THE INVENTION- Broadly speaking, the present invention resides in a method for encapsulating components which comprises covering desired portions of the components with a composition consisting essentially of a mi-xture of an epoxy resin, specific amounts of chopped graphite and/or boron nitride fibers, and a curing agent; and

curing the composition so as to form a solid epoxy resin covering the portions of the components. In another embodiment the invention lies in the composition which is utilized in the encapsulation method. It has been discovered that the composition possesses a very low coefficient of linear thermal expansion, a property which renders it particularly suitable for use as a potting composition for delicate components.

Any of the well known epoxy resins can be utilized in the practice of the present invention so long as they are pourable, or canbe rendered pourable, at about room temperature. Thus, a resin having a viscosity such that it is to'o thick to pour; can be made to pour readily by the addition. of a monofunctional epoxy diluent, such as I butyl glycidyl ether. In general, the epoxy resins contain more than one epoxy group, i.e., a cyclic ether group in which an ether oxygen atom is attached to two adjacent carbon atoms. Epoxy resins that are preferred are those obtained by reacting a polyhydric phenol with a polyfunc tional halohydrin. Exemplary polyhydric phenols include resorcinol. and various bisphenols derived from the condensation of phenol with aldehydes and ketones such as formaldehyde, acetaldehyde, acetone, methyl ethyl ketone, and the like. A particularly preferred epoxy resin of this class of resins is the condensation product of epichlorohydrin and bisphenol A [2,2-bis(p-hydroxyphenyl)propane]. This resin has the following structural formula:

late electrical, optical and mechanical components. Of I wherein n has a value such that the resin is liquid at room temperature. Generally n is equal to zero or to an integer from 1 to 4, inclusive. Commercially available liquid diglycidyl ethers of bisphenol A according to the above formula are Epon-815, 820, 826, 828 and 830 resins of Shell Chemical Company. Certain properties of these resins are shown below in the table.

Melting Viscosity, poises Epoxide" Resin Point, "C at 25C Equivalent Epon 815 Liquid 5-7 -195 Epon 820. Liquid 40-100 -195 Epon 826 Liquid 65-95 180-188 Epon 828 Liquid 100-160 -192 Epon 830 Liquid 150-225 -210 "Grams of resin containin one Arn-e uivalent ofe xide.

Thegraphite and/or boron nitride fibers used in the practice'of the present invention are available from commercial sources. The as-received fibers are chopped or cut to a length, e.g., 0.25 to 0.75 inch, suitable for blending with the epoxy resin. In the blending 7 be employed in curing or crosslinking the epoxy resins used in'practicing the present invention. Amines, such as aromatic and aliphatic primary, secondary and tertiary amines, have been found to be especially suitable. Examples of such curing agents include phenylenediamine, ethylenediarnine, triethylenetetraa mine, diethylenetriamine, diethylaminopropylamine,

- methylenedianiline, diaminodiphenyl sulfone, and the like. Anhydrides of carboxylic acid are also suitable for use as curing agents. Examples 'of this class of compounds include adipic, maleic, 'phthalic, dodecenylsuccinic, and trimellitic anhydrides. It is usually preferred in the range of about to 15 parts by weight per 100 parts by weight of the epoxy resin. Curing of the epoxy resin composition is preferably conducted at room temperature for a period of about 18 to 48 hours. However,

of 100 grams was poured into the blender after which the fiber segments were added. It was found that optimum mixing was obtained by adding the fiber segments in increments of 5 pph of resin.

higher temperatures can be employed, e.g., from about 5 Mixing of the resin and fibers was conducted for a room temperature to 100C, in which case shorter curperiod of time sufficient to provide a homogeneous ing times can be used. blend. The actual mixing time ranged from about to A better understanding of the invention can be ob- 25 seconds. Initially, the mixing caused cavitation and tained by referring to the following illustrative examsome fibers were deposited on the sides of the blender ples which are not intended, however, to be unduly 1im above the resin level. The mixing was then terminated itative of the invention. after which the fibers were scraped from the sides and de sited in the resin. When a homo eneous mixture EXAMPLE] p0 g was formed, the mixture no longer cavitated and the A series of runs was conducted in which the potting blender had a smooth mixing sound. compositions of this invention were prepared and cer- During the blending operation, the mixture increased tain properties of the cured compositions were deterin temperature as a result of heat transfer from the mined. The epoxy resin utilized was Epon 815 which, motor assembly to the mixture. The mixture was alas received from the supplier, contained 11 percent of lowed to cool to room temperature while under a vaca monofunctional epoxy diluent (butyl glycidyl ether). uum to remove entrapped air. After the mixture had The discontinuous graphite fibers were obtained from cooled to room temperature, 11 pph of diethylenetri- Thornel continuous graphite yarns sold by Union Caramine, the curing agent, was added to the blend. The bide Corp. The boron nitride fibers, which were supcompositions so prepared were cured at room temperaplied in mat form, were obtained from the Carborunture for a minimum of 16 hours prior to mechanical dum Corp. Properties of the components used in preand physical testing. A control run was also carried out paring the potting compositions are shown below in in which the same resin and curing agent were used but Table I. no fibers were added. The results of the tests are set TABLE 1 Thornel Thornel Thornel Epon Property 25 50 75 EN 815 Tensile Modulus,

10 psi 25 50 75 4-6 .46 Tensile Strength,

10 psi 180 320 375 50-100 157 Density, g/cc 1.42 1.68 1.85 1.8-2.0 1.16 Coefi. of Linear Thermal Exp.

10- in/in/C --.445 .800 .733 2.9 10 54.3 M Plies 2 2 2 Supplied Filaments/ply 720 720 720 in Twist/inch 1.5 1.5 1.5 mat form Cured resin obtained by mixing with l l pph (parts per hundred by Weight) of diethylenetriamine (DTA) and curing at room temperature.

"Determined from Xray analysis of single Crystals as reported by Niedenzer and Dawson. Boron-Nitrogen Compounds, U.S. Army Research Office, Duke University. Academic Press Inc.. New York (1965 In preparing the cured potting composition, the proforth below in Table 11 which also shows the amount of fibers contained in the compositions. As seen from the data in the table, the compositions had a coefiicient of linear thermal expansion in the range of about 12Xl0 to 35 1O in/in/C when the compositions contained an amount of fibers ranging from about 10 to 16 pph.

TABLE 11 Density 10 Modulus Strength! Resistivity' Fiber" PPH g/cc in/in/C 10 psi 10 psi ohm/cm Control 0 1.16 54.3 .46 15.7 8.7 X 10 Thornel 25 5 1.17 48.6 .45 8.5 Thornel 25 10 1.01 35.8 .61 l 1.3 Thornel 25 14 1.44 26.4 .78 12.6 Thornel 25 16 1.19 26.9 .69 13.7 Thornel 50 5 1.19 26.3 .42 12.9 6.7 X 10 Thornel 5O 10 1.19 19.7 .53 11.4 11.4 X 10 Thornel 5O 14 1.18 13.4 .65 13.8 18.9 X 10 Thornel 50 16 1.18 13.4 .60 12.6 7.6 X 10 Thornel 5 1.19 25.5 .54 12.1 1.14 X 10 Thornel 75 10 1.22 19.9 .90 12.9 1.14 X 10 Thomel75 14 16.4 1.13 15.3 1.18X10 Thornel 75 16 1.23 12.3 1.28 16.3 4.9 X 10 BN 5 1.18 51.7 .39 13.0 4.93 X 10 EN 10 1.20 43.7 .39 8.9 3.00 X 10" EN 14 1.21 32.8 .44 13.1 6.9 X 10 BN/Thornel 75 5/10 1.20 18.4 .92 19.0 9.13 X 10" TABLE lI-continued all) Density" IO Modulus Strength, Resistivity Fiber PPH g/cc in/in/"C psi lO psi ohm/cm BN/Thomel 75 10/5 1.19 28.8 .84 13.6 1.07 X 10 Fiber lengths were measured from 250x photographs of thecured potting compounds. The average length of fibers for all compositions was about 0.003 inch as indicated from sample determinations. Density was determined by water immersion.

""l'l'te method and apparatus for determining the coefficient of linear thermal expansion (or) were similar to those described in ASlM D-696-70. The Specimens used were rectangular in cross section having overall dimensions of2.0" X 0.375" X 0.250". The coefficient for the compositions was determined from 30 2C to +30 2C. A minimum of 2 tests was conducted for each value of 1: shown in the table.

'Flexural strength and modulus were obtained from the same s ecimens that were used for determining the coefficients of thermal expansion. The tests were conducted using procedures of Federal Test S ecification L-P406b as a guide. The 3-point loading method was employed with a span to depth ratio of lo to l. Specimens were tested at a crosshead rate of 0.05 in/min.

Resistivity measurements were made with a Beckman Mcgohmmeter. Model L-8. following the procedure outlined in ASI'M D- 257-66, Specimens were 3" in diameter and 0.125" thick.

EXAMPLE ll l l pph of DTA while the second sensor is covered with Epon 815 resin containing 16 pph of Thornel 50 discontinuous graphite fibers and 11 pph of DTA. The coatings of the sensors are allowed to cure at room temperature for 20 hours. At the end of this period, the sensors are adhesively bonded at an elevated temperature to a re-entry space vehicle. As a result of thermally induced compressive forces, the first sensor is rendered inoperative. However, the bonding operation has no adverse effect upon the second sensor that is encapsulated with the composition of this invention.

As disclosed in the literature, fillers are used extensively to modify epoxy resin so as to obtain products having desired properties. Modification of epoxy potting compounds to reduce their coefficient of linear thermal expansion (0:) has been accomplished by compounding the resins with fillers such as aluminum oxide, calcium carbonate, silica, lithium aluminosilicate, iron powder, aluminum powder and copper powder. In FIG. 1 of the drawing, curves are shown that illustrate the reduction of a versus the amount of a particular filler. The curves have been taken from the Handbook of Epoxy Resins by Lee and Neville, McGraw-l-lill, Inc. From a consideration of the curves, it is seen that very large quantities of filler are required to obtain significant reductions in a. FIG. 2 of the drawing shows curves that have been plotted from the data recorded in Table [1. As seen from these curves, only a comparatively small amount of the choppedfibers are required in order to obtain a reduction in a that is much greater than that obtained with fillers disclosed in the prior art.

As will be evident to those skilled in the art, modifi- CH 7 i ca ca ca 3 PH 983 ca cn 3 n 3 cation of the invention can be made in view of the foregoing disclosure without departing from the spirit and scope of the invention.

I claim:

1. A method of encapsulating structurally delicate 7 electrical, optical and mechanical components which comprises covering portions of the components with a composition with a low coefficient of thermal expan-' sion consisting essentially of a pourable, homogeneous mixture of an epoxy resin, discontinuous fibers having phenol and a polyfunctional halohydrin.

3. The method according to claim 2 in which the epoxy resin has the following structural formula: wherein n has a value of 0-4 such that the resin is pourable at room temperature.

4. The method according to claim 1 in'which the amount of curing agent in the mixture is in the range of about 5 to 15 parts by weight per lOO parts by weight of epoxy resin. 5. The method according to claim 4 in which the curing agent is selected from the group consisting of aromatic and aliphatic primary, secondary and tertiary amines, and anhydrides of carboxylic acids.

6. The method according to claim 1 in which the composition is cured by maintaining the composition at room temperature for a period of about 18 to 48 hours. 

1. A METHOD OF ENCAPSULATING STRUCTURALLY DELICATE ELECTRICAL OPTICAL AND MECHANICAL COMPONENTS WHICH COMPRISES COVERING PORTIONS OF THE COMPONENTS WITH A COMPOSITION WITH A LOW COEFFICIENT OF THERMAL EXPANSION CONSISTING ESSENTIALLY OF A POURABLE, HOMOGENEOUS MIXTURE OF AN EPOXY RESIN, DISCONTINOUS FIBERS HAVING A LENGTH IN THE RANGE OF 1 TO 10 MILS, THE FIBERS BEGIN SELECTED FROM THE GROUP CONSISTING GRAPHITE FIBERS, BORON NITRIDE FIBERS AND MIXTURE THEREOF, THE AMOUNT OF DISCONTINUOUS FIBERS BEGIN IN THE RANGE OF 10 TO 16 PARTS BY WEIGHT PER 100 PARTS BY WEIGHT OF EPOXY RESIN, AND A CURING AGENT FOR THE EPOXY RESIN, AND DURING THE COMPOSITION SO AS TO FORM A SOLID EPOXY RESIN COVERING THE PORTION OF THE COMPONENTS.
 2. The method according to claim 1 in which the epoxy resin is the condensation product of a polyhydric phenol and a polyfunctional halohydrin.
 3. The method according to claim 2 in which the epoxy resin has the following structural formula:
 4. The method according to claim 1 in which the amount of curing agent in the mixture is in the range of about 5 to 15 parts by weight per 100 parts by weight of epoxy resin.
 5. The method according to claim 4 in which the curing agent is selected from the group consisting of aromatic and aliphatic primary, secondary and tertiary amines, and anhydrides of carboxylic acids.
 6. The method according to claim 1 in which the composition is cured by maintaining the composition at room temperature for a period of about 18 to 48 hours. 